Method of manufacturing heat sink frames

ABSTRACT

A method of manufacturing heat sink frames comprises the steps of: extruding an aluminum material to form a heat sink model; shearing multiple portions on a length of the heat sink model where are desired to be bent to form a plurality of shearing notches according to required dimension specification; bending the heat sink model at the shearing notches to form a plurality of bend angles through respectively connecting edges of each of the shearing notches; and fastening a front end of the heat sink model to a rear end of the heat sink model to form a frame. Through extruding, shearing and bending processes, fabrication is simpler and material and labor hours can be saved to enhance heat conduction efficiency and reduce production cost.

FIELD OF THE INVENTION

The present invention relates to a method of manufacturing heat sink frames and particularly to a method of manufacturing a heat sink structure for LCD backlight modules.

BACKGROUND OF THE INVENTION

Liquid crystal display (LCD) has many advantages, such as slimmer, lighter, lower radiation and lower power consumption, thus has fully replaced the traditional cathode ray tube (CRT) in few years and become the mainstream of information product on the market. Because the LCD panel does not generate light, a backlight module has to be deployed at the rear side of the LCD panel to provide light needed.

The conventional backlight module uses cold cathode fluorescent lamp (CCFL) which has many disadvantages, such as containing mercury, and also is inferior to the LED (Light Emitting Diode) in terms of response speed, monochromatism, volume and power consumption. The prevailing trend of LCD at present is towards greater dimension, slimmer and lighter. Hence LED has gradually displaced CCFL and becomes the main backlight source of new generation of LCD.

Although the LED has the advantages of smaller size, greater luminosity and lower power consumption, it generates heat during photoelectric conversion that creates problems such as chromatic polarization. Thus how to prevent high temperature from affecting product reliability and lifespan through cooling technique has become an urgent issue in the industry.

FIG. 1 illustrates a conventional backlight module cooling apparatus 1 of an LCD. It includes a plurality of LED modules 11, a plurality of heat sink plates 12 and a metal back panel 13. The LED modules 11 are mounted respectively on the heat sink plate 12 which is further fastened to the metal back panel 13. When the LED modules 11 are in use, heat generated therefrom is transmitted to the metal back panel 13 via the heat sink plates 12 and dissipated outside the LCD. Such a structure is difficult to assemble. The heat sink plates 12 and metal back panel 13 are contacted with each other, thus heat is hard to be transmitted. Moreover, different specifications of molds for the heat sink plates 12 and metal back panel 13 have to be individually fabricated to match varying sizes of LCDs that results in higher production cost. There is still room for improvement.

SUMMARY OF THE INVENTION

The primary object of the present invention is to provide a method of manufacturing heat sink frames to overcome the drawbacks of the cooling structure of conventional backlight modules that have limited heat conduction efficiency and higher production cost.

To achieve the foregoing object, the method of manufacturing heat sink frames according to the invention comprises the steps as follows: extruding an aluminum material to form a heat sink model; shearing multiple portions on a length of the heat sink model where are desired to be bent to form a plurality of shearing notches according to required dimension specification; bending the heat sink model at the shearing notches to form a plurality of bend angles through respectively connecting edges of each of the shearing notches; and fastening a front end of the heat sink model to a rear end of the heat sink model to form a frame.

The step of fastening the front end to the rear end of the heat sink model can be done via stamping and riveting or wedging. The edges of the shearing notch and the front and rear ends of the heat sink model respectively have a plurality of apertures which are riveted by a plurality of bumps formed on a riveting plate via stamping, thereby a frame is tightly formed.

Alternatively, the edges of the shearing notch and the front and rear ends of the heat sink model may respectively have a dovetail saddle and a dovetail groove. The dovetail saddle is wedged in the dovetail groove to form a frame.

The method provided by the invention has many advantages, notably:

1. The heat sink frame manufactured by the method of the invention is formed integrally, hence can save fabrication process and labor hours, and also can overcome the drawback of the conventional backlight module that the heat conduction efficiency is lower after the back panel and heat sink plate are coupled.

2. The heat sink frame of the invention is formed by extrusion, thus its length is not limited and can be adaptable to various specifications of backlight modules. Moreover, only if the shearing notches are formed at desired locations according to required dimension specifications, the need of fabricating molds according to different dimensions can be eliminated, thus production cost can be reduced significantly. Practicality and usability improve.

The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cooling structure of a conventional backlight module.

FIG. 2 is a flowchart of the method of manufacturing heat sink frames according to the invention.

FIG. 3 is a schematic view of an extruded heat sink model according to the invention.

FIG. 4A is a schematic view showing the heat sink model with a plurality of shearing notches according to a first embodiment of the invention.

FIG. 4B is a fragmentary enlarged view according to FIG. 4A.

FIG. 5 is a schematic view showing the heat sink model with its front end and rear end coupled together according to the first embodiment of the invention.

FIG. 6 is a cross section taken on line A-A in FIG. 5.

FIG. 7 is a schematic view showing a finished product according to the first embodiment of the invention.

FIG. 8 is a schematic view showing the heat sink model in a bending condition according to a second embodiment of the invention.

FIG. 9 is a schematic view showing the heat sink model in a coupling condition according to the second embodiment of the invention.

FIG. 10 is a schematic view showing a finished product according to the second embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Please refer to FIG. 2, the invention aims to provide a method of manufacturing heat sink frames. The method comprises the steps of:

a. S2: Extruding an aluminum material to form a heat sink model;

b. S3: Shearing multiple portions on a length of the heat sink model where are desired to be bent to form a plurality of shearing notches according to required dimension specification;

c. S4: Bending the heat sink model at the shearing notches to form a plurality of bend angles through respectively connecting edges of each of the shearing notches; and

d. S5: Fastening a front end of the heat sink model to a rear end of the heat sink model to form a frame via stamping and riveting or wedging.

Please refer to FIGS. 3 through 6 for a first embodiment of the invention. First, a heat sink model 6 is fabricated via extruding an aluminum material. The length of the heat sink model 6 is adjustable according to actual requirements. Next, a plurality of shearing notches 61 are formed via shearing at selected portions on a length of the heat sink model 6 where are desired to be bent according to required dimension specification. The edges of each shearing notch 61 and the front and rear ends of the heat sink model 6 respectively include a plurality of apertures 62. Then the heat sink model 6 is bent at the shearing notches 61 to form a plurality of bend angles 63 through respectively connecting the edges of each shearing notch 61. Finally, the apertures 62 are riveted by a plurality of bumps 71 formed on a riveting plate 7 via stamping to form the frame 8 tightly.

FIG. 7 illustrates a finished product fabricated according to the method previously discussed. It includes a frame 8 and a plurality of riveting plates 7. The frame 8 is formed by bending the heat sink model 6 that is formed by extruding an aluminum material and has a plurality of bend angles 63 each has a shearing notch 61 on the inner side. The edges of the shearing notch 61 and the front and rear ends of the heat sink model 6 respectively include a plurality of apertures 62. Each riveting plate 7 has a plurality of bumps 71 corresponding to the apertures 62. The apertures 62 are riveted by the bumps 71 of the riveting plate 7 via stamping to integrally form the frame 8 tightly.

Please refer to FIGS. 8 through 10 for a second embodiment of the invention. First, a heat sink model 6 a is fabricated via extruding an aluminum material. Next, a plurality of shearing notches 61 a are formed via shearing at selected portions on the heat sink model 6 a where are desired to be bent. The edges of each shearing notch 61 a and the front and rear ends of the heat sink model 6 a respectively include a dovetail saddle 611 and a mating dovetail groove 612. Then the heat sink model 6 a is bent at the shearing notches 61 a to form a plurality of bend angles 63 a through respectively connecting the edges of each shearing notch 61 a. Finally, the dovetail saddle 611 is wedged in the dovetail groove 612 to form a frame 8 a.

As a conclusion, the method of manufacturing heat sink frames provided by the invention can eliminate the shortcomings of the conventional techniques and improve practicality and usability.

While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention. 

What is claimed is:
 1. A method of manufacturing heat sink frames, comprising the steps of: a. extruding an aluminum material to form a heat sink model; b. shearing multiple portions on a length of the heat sink model where are desired to be bent to form a plurality of shearing notches according to required dimension specification; c. bending the heat sink model at the plurality of shearing notches to form a plurality of bend angles through respectively connecting edges of each of the plurality of shearing notches; and d. fastening a front end of the heat sink model to a rear end of the heat sink model to form a frame.
 2. The method of claim 1, wherein the step of fastening the front end to the rear end of the heat sink model is selectively performed via stamping and riveting or wedging.
 3. The method of claim 2, wherein the edges of the shearing notch and the front and rear ends of the heat sink model respectively include a plurality of apertures which are riveted by a plurality of bumps of a riveting plate via stamping to form the frame tightly.
 4. The method of claim 2, wherein the edges of the shearing notch and the front and rear ends of the heat sink model respectively include a dovetail saddle and a dovetail groove, the dovetail saddle being wedged in the dovetail groove to form the frame. 